Hoshizaki HUR40A-D User manual

Hoshizaki
“A Superior Degree
of Reliability”
www.hoshizaki.com
Models
Refrigerators
HUR40A(-D) HWR40A(-D)
HUR68A(-D) HWR68A(-D)
HUR96A(-D) HWR96A(-D)
Freezers
HUF40A(-D) HWF40A(-D)
HUF68A(-D) HWF68A(-D)
Commercial Refrigerators & Freezers
Undercounter & Worktop Series
Hoshizaki America, Inc.
Number: 73123
Issued: 2-4-2005
Revised: 9-30-2008
SERVICE MANUAL

2
IMPORTANT
Only qualied service technicians should attempt to service or maintain this
unit. No such service or maintenance should be undertaken until the technician
has thoroughly read this Service Manual.
Hoshizaki provides this manual primarily to assist qualied service technicians in the
service and maintenance of the unit.
Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call, write or send an e-mail message to the Hoshizaki Technical
Support Department for assistance.
HOSHIZAKI AMERICA, INC.
618 Highway 74 South
Peachtree City, GA 30269
Attn: Hoshizaki Technical Support Department
Phone: [phone] Technical Support
[phone]
Fax: [phone]
[phone]
E-mail: [email protected]
Web Site: www.hoshizaki.com
NOTE: To expedite assistance, all correspondence/communication MUST include the
following information:
   •ModelNumber__________________________
   •SerialNumber__________________________
   •Completeanddetailedexplanationoftheproblem.
ENERGY STAR®
Products earning the ENERGY STAR prevent greenhouse gas emissions by meeting strict
energy efficiency guidelines set by the U.S. Environmental Protection Agency and the
U.S. Department of Energy. Several models of Hoshizaki undercounters have earned the
ENERGY STAR. To easily determine if your unit has earned the ENERGY STAR, see the
nameplate attached to the right wall on the inside of the cabinet.

3
CONTENTS
I. Specications...................................................................................................................... 5
A. Nameplate Ratings........................................................................................................ 5
B. Dimensions ................................................................................................................... 5
1. HUR40A, HUF40A ................................................................................................... 6
1a. HUR40A-D, HUF40A-D ......................................................................................... 6
2. HWR40A, HWF40A................................................................................................. 7
2a. HWR40A-D, HWF40A-D........................................................................................ 7
3. HUR68A, HUF68A .................................................................................................. 8
3a. HUR68A-D, HUF68A-D ......................................................................................... 8
4. HWR68A, HWF68A................................................................................................. 9
4a. HWR68A-D, HWF68A-D........................................................................................ 9
5. HUR96A ................................................................................................................ 10
5a. HUR96A-D........................................................................................................... 10
6. HWR96A ................................................................................................................11
6a. HWR96A-D...........................................................................................................11
II. General Information ........................................................................................................ 12
A. Construction................................................................................................................ 12
B. Sequence of Operation and Timing Charts................................................................. 13
1. Refrigerators – Continuous Operating Mode ......................................................... 13
2. Freezers – Continuous Operating Mode .............................................................. 15
3. Refrigerators – Energy Saving Operating Mode ................................................... 17
4. Freezers – Energy Saving Operating Mode .......................................................... 19
C. Control Board .............................................................................................................. 21
1. Start-Up Delay........................................................................................................ 21
2. Control Board Layout............................................................................................. 22
D. Settings and Diagnostics............................................................................................. 23
1. Gaining Access to Settings and Diagnostics .......................................................... 23
2. Temperature Display .............................................................................................. 24
a) Switching the Display Between Fahrenheit and Celsius (F5) .......................... 24
b) Adjusting the Setpoint Temperature ................................................................. 24
c) Cabinet Temperature Correction (calibration factor)......................................... 25
3. Settings and Diagnostics Menu ............................................................................. 26
a) Defrost Interval (F0)......................................................................................... 27
b) Defrost Termination Temperature (F1) ............................................................. 27
c) Setpoint Temperature Differential (F2).............................................................. 28
d) High Temperature Alarm Delay Time (F3)........................................................ 29
e) Low Temperature Alarm Delay Time (F4)......................................................... 29
f) Temperature Display Scale (F5)........................................................................ 30
g) Alarm History (F6)............................................................................................ 30
h) Compressor Run Time (F7) ............................................................................. 31
Please review this manual. It should be read carefully before the unit is serviced or
maintenance operations are performed. Only qualied service technicians should service
and maintain the unit. This manual should be made available to the technician prior to
service or maintenance.

4
4. Operating Modes ................................................................................................... 31
a) Continuous....................................................................................................... 32
b) Energy Saving.................................................................................................. 32
c) Automatic Corrections Made During Energy Saving Operating Mode.............. 32
E. Perimeter Frame Heater.............................................................................................. 32
III. Service Diagnosis........................................................................................................... 33
A. Alarm Codes ............................................................................................................... 33
1. Alarm Display Priority............................................................................................. 34
2. Alarm Details and Countermeasures..................................................................... 35
a. High Temperature Alarm (E1)........................................................................... 35
b. Low Temperature Alarm (E2)............................................................................ 36
c. Defrost Alarm (E3)............................................................................................ 37
d. High Pressure Alarm (E4)................................................................................. 37
e. Clogged Filter Alarm (E7) ................................................................................. 38
f. Defrost Temperature Sensor Malfunction Alarm (E8) ........................................ 39
g. Clogged Filter Sensor Malfunction Alarm (E9) ................................................. 40
h. Control Board Error Alarms (EA and ED) ......................................................... 41
B. Diagnosis Chart .......................................................................................................... 42
C. Thermistor Check........................................................................................................ 45
IV. Removal and Replacement of Components ................................................................... 46
A. Service for Refrigerant Lines....................................................................................... 46
1. Refrigerant Recovery ............................................................................................. 46
2. Brazing .................................................................................................................. 46
3. Evacuation and Recharge .................................................................................... 47
B. Removal and Replacement of Refrigeration Unit ........................................................ 48
C. Removal and Replacement of Compressor ................................................................ 48
D. Removal and Replacement of Evaporator................................................................... 49
E. Removal and Replacement of Capillary Tube / Suction Line Assembly ...................... 51
F. Removal and Replacement of Thermistors .................................................................. 52
G. Removal and Replacement of Door Gasket ............................................................... 53
H. Removal and Replacement of Defrost Heater............................................................. 53
I. Removal and Replacement of Control Board ............................................................... 54
J. Removal and Replacement of Fan Motors................................................................... 55
K. Door Re-Hinging and Drawer Conversion ................................................................... 55
V. Cleaning and Maintenance Instructions........................................................................... 56
A. Cleaning...................................................................................................................... 56
B. Maintenance................................................................................................................ 57
VI. Wiring Diagrams ............................................................................................................ 58
A1. HUR40A, HWR40A (auxiliary code Q5 and earlier) .................................................. 58
A2. HUR40A(-D), HWR40A(-D) (auxiliary code Q6 and later) ....................................... 59
B. HUF40A(-D), HWF40A(-D) ......................................................................................... 60
C1. HUR68A, HWR68A (auxiliary code Q5 and earlier).................................................. 61
C2. HUR68A(-D), HWR68A(-D) (auxiliary code Q6 and later) ........................................ 62
D. HUF68A(-D), HWF68A(-D) ......................................................................................... 63
E. HUR96A(-D), HWR96A(-D)......................................................................................... 64

5
Undercounter Model Names
The undercounter models covered in this service manual initially had different model
names. If you have a unit with an auxiliary code of N-6 and a serial number ending in "H",
refer to the table below.
Model Name on
Nameplate
Current
Name
UR1-SSB HUR40A
UR2-SSB HUR68A
UF1-SSB HUF40A
UF2-SSB HUF68A
I. Specications
A. Nameplate Ratings
Design Pressure
(PSIG)
Refrigerant
(oz.)
Model AC Supply Voltage Amperes HI LO 404A 134a
HUR40A(-D), HWR40A(-D) 115/60/1 5.0 240 120 15.2
HUR68A(-D), HWR68A(-D) 115/60/1 5.0 240 120 15.2
HUR96A(-D), HWR96A(-D) 115/60/1 6.0 240 120 15.2
HUF40A(-D), HWF40A(-D) 115/60/1 5.5 450 250 14.1
HUF68A(-D), HWF68A(-D) 115/60/1 10.0 450 250 13.0
Model
Door Opening mm Total Refrigerated
Volume ft3
Total Shelf
Space ft2
Hotel Pan
Capacity (-D)
Width Height
HUR40A(-D), HWR40A(-D),
HUF40A(-D), HWF40A(-D)
570.2 616.2
8.5 7. 6 4
HUR68A(-D), HWR68A(-D),
HUF68A(-D), HWF68A(-D)
18.8 1 7. 1 8
HUR96A(-D), HWR96A(-D) 29.1 26.6 12
B. Dimensions

6
Units: mm (in.)
1a. HUR40A-D, HUF40A-D
1. HUR40A, HUF40A

7
2. HWR40A, HWF40A
Units: mm (in.)
2a. HWR40A-D, HWF40A-D

8
3. HUR68A, HUF68A
Units: mm (in.)
3a. HUR68A-D, HUF68A-D

9
4. HWR68A, HWF68A
Units: mm (in.)
4a. HWR68A-D, HWF68A-D

10
5. HUR96A
5a. HUR96A-D
Units: mm (in.)

11
6a. HWR96A-D
6. HWR96A
Units: mm (in.)

12
Compressor Base
Condenser Fan Motor
Front Panel
Evaporator Case Cover
Control Box
Compressor
Side Panel
Evaporator Case
Capillary Tube/Suction
Line Assembly
Condenser
Evaporator Assembly
Access Valve (Low-Side)
Cabinet Thermistor
Thermal Fuse
Evaporator Case Cover
Evaporator Fan Motor
Evaporator
Defrost Heater
Defrost Thermistor
Evaporator Shroud
Defrost Thermostat
Evaporator Case
II. General Information
A. Construction
Hoshizaki undercounters feature a cartridge-type refrigeration unit that can be removed
without taking off the top and side panels.

13
Note:
1) Cut-on, cut-off, and cabinet temperature are read by the same sensor, called the
"cabinet thermistor."
2) The defrost thermistor reads the evaporator temperature.
3) There is a ve second evaporator fan startup delay when the compressor and
fan would otherwise start together.
B. Sequence of Operation and Timing Charts
For details on operating modes, see "II.D.4. Operating Modes."
1. Refrigerators – Continuous Operating Mode
a) Sequence of Operation
Five minutes after
defrost heater off
1. Compressor on
2. Condenser fan on
Five minutes after
compressor start-up
1. Evaporator fan(s) on
2. Frame heater(s) on
(Q6 and later)
One minute after evaporator
fan start-up "dF" no
longer displayed, cabinet
temperature displayed
Board Self Check
1. Frame heater(s) on
2. Evaporator fan(s) on
POWER ON
2-minute Delay
1. Compressor start-up
2. Condenser fan start-up
Cycle Off (Cut-out
temperature reached)
[Minimum 2 minutes]
1. Compressor off
2. Condenser fan off
Continue as
normal cycling
Cycle On (Cut-on
temperature reached)
[Minimum 2 minutes]
1. Compressor start-up
2. Condenser fan start-up
Defrost End
Defrost thermistor
reaches defrost
termination temperature,
or defrost timer reaches
1 hour
Defrost heater off
Defrost Start
Preprogrammed time interval
1. Compressor off
2. Evaporator fan(s) off
3. Frame heater(s) off (Q6 and later)
4. Condenser fan off
5. Defrost heater on
6. "dF" displayed

14
b) Timing Chart
Refrigerators – Continuous Operating Mode
NO
FFO
NO
FFO FFO
NO NO
FFO
)+(laitnereffiD+tniopteS
)--(laitnereffiD+tniopteS
gninaemoN
NO
FFO
NO
FFO
rotsimrehTtenibaC
rotsimrehTtsorfeD
osserpmoC
r
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n(s)aFrotaropavE
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.nim2
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erutarepmeTnoitanimreTtsorfeD
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TIME-TEMPERATURE CONTROL CHART ENERGY SAVING MODE REFRIGERATORS
Q6 and Later
Q5 and Earlier
Frame Heater(s)

15
2. Freezers – Continuous Operating Mode
a) Sequence of Operation
Note:
1) Cut-on, cut-off, and cabinet temperature are read by the same sensor, called the
"cabinet thermistor."
2) The defrost thermistor reads the evaporator temperature.
3) There is a ve second evaporator fan startup delay when the compressor and
fan would otherwise start together.
Five minutes after
defrost heater off
1. Compressor on
2. Condenser fan on
Five minutes after
compressor start-up
1. Evaporator fan(s) on
Eight minutes after evaporator
fan start-up "dF" no longer
displayed, cabinet temperature
displayed
Board Self Check
1. Frame heater(s) on
2. Evaporator fan(s) on
POWER ON
2 minute delay
1. Compressor start-up
2. Condenser fan start-up
Cycle Off (Cut-out
temperature reached)
[Minimum 2 minutes]
1. Compressor off
2. Condenser fan off
Continue as
normal cycling
Cycle On (Cut-on
temperature reached)
[Minimum 2 minutes]
1. Compressor start-up
2. Condenser fan start-up
Defrost end
Defrost thermistor
reaches defrost
termination
temperature, or defrost
timer reaches 1 hour
Defrost heater off
Defrost Start
Preprogrammed time interval
1. Compressor off
2. Evaporator fan(s) off
3. Condenser fan off
4. Defrost heater on
5. "dF" displayed

16
b) Timing Chart
Freezers – Continuous Operating Mode
NO
FFO
NO
FFO
)+(laitnereffiD+tniopteS
)--(laitnereffiD+tniopteS
gninaemoN
FFO
NO NO
FFO
NO
FFO
NO
FFO
otsimrehTtenibaC
r
otsimrehTtsorfeD
r
osserpmoC
r
naFresnednoC
n(s)aFrotaropavE
etaeHtsorfeD
r
.nim2
)yaleDtratS(
NOrewoP
emiT sruoh6
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.nim5
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r
.nim8
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TIME-TEMPERATURE CONTROL CHART [NOT DURING ENERGY SAVING MODE] FOR
REFRIGERATORS & FREEZERS WITH AUXILIARY CODE _____ AND BEFORE
Frame Heater(s)

17
3. Refrigerators – Energy Saving Operating Mode
a) Sequence of Operation
Note:
1) Cut-on, cut-off, and cabinet temperature are read by the same sensor, called the "cabinet
thermistor."
2) The defrost thermistor reads the evaporator temperature.
Defrost End
Defrost thermistor
reaches defrost
termination temperature,
or defrost timer reaches
1 hour
Defrost heater off
Defrost Start
Preprogrammed time interval
1. Compressor off
2. Frame heater(s) off (Q6 and later)
3. Evaporator fan(s) off
4. Condenser fan off
5. Defrost heater on
6. "dF" displayed
Five minutes after
defrost heater off
1. Compressor on
2. Condenser fan on
Five minutes after
compressor start-up
1. Evaporator fan(s) on
2. Frame heater(s)
on (Q6 and later)
Board Self Check
1. Frame heater(s) on continuously
(Q5 and earlier)
Frame heater(s) cycle on and off
(Q6 and later)
2. Evaporator fan(s) cycles on and off
POWER ON
2-minute Delay
1. Compressor start-up
2. Condenser fan start-up
3. Frame heater(s) on
(continuously)
4. Evaporator fan(s) on
(continuously)
Cycle Off (Cut-out
temperature reached)
[Minimum 2 minutes]
1. Compressor off
2. Condenser fan off
3. Frame heater(s)
cycle on and off
(Q6 and later)
4. Evaporator fan(s)
cycles on and off
Continue as
normal cycling
Cycle On (Cut-on
temperature reached)
[Minimum 2 minutes]
1. Compressor start-up
2. Condenser fan start-up
3. Frame heater(s) on
(continuously)
4. Evaporator fan(s) on
(continuously)
One minute after evaporator
fan start-up "dF" no longer
displayed, cabinet temperature
displayed

18
b) Timing Chart
Refrigerators – Energy Saving Operating Mode
NO
FFO
NO
FFO
)+(laitnereffiD+tniopteS
)--(laitnereffiD+tniopteS
gninaemoN
FFO
NO NO
FFO
NO
FFO
NO
FFO
rotsimrehTtenibaC
rotsimrehTtsorfeD
osserpmoC
r
naFresnednoC
n(s)aFrotaropavE
etaeHtsorfeD
r
.nim2
)yaleDtratS(
NOrewoP
emiT sruoh6
)elbatsujdA-tratStsorfeD(
.nim5
)yaleDniarD(
.nim5
)yaleDnaF(
rotacidnItsorfeD .nim1
)yaleDyalpsiD(
erutarepmeTnoitanimreTtsorfeD
.nim06<
)noitaruDtsorfeD.xaM(
tnettimretnI
noitarepO
)sdoirePFFOrosserpmoCllA(
tnettimretnI
noitarepO
)sdoirePFFOrosserpmoCllA(
TIME-TEMPERATURE CONTROL CHART [DURING ENERGY SAVING MODE] FOR
REFRIGERATORS WITH AUXILIARY CODE _____ AND AFTER
*
*
nehwyaledputratsnafrotaropavednoceseviF
rehtegottratsesiwrehtodluownafdnarosserpmoc
Q5 and Earlier
Q6 and Later
*
*
Frame Heater(s)
.nim2
)NO.niM(
.nim2
)FFO.niM(

19
4. Freezers – Energy Saving Operating Mode
a) Sequence of Operation
Note:
1) Cut-on, cut-off, and cabinet temperature are read by the same sensor, called the "cabinet
thermistor."
2) The defrost thermistor reads the evaporator temperature.
Five minutes after
defrost heater off
1. Compressor on
2. Condenser fan on
Five minutes after
compressor start-up
1. Evaporator fan(s) on
Eight minutes after evaporator
fan start-up "dF" no longer
displayed, cabinet temperature
displayed
Board Self Check
1. Frame heater(s) on
2. Evaporator fan(s)
cycles on and off
POWER ON
2-minute Delay
1. Compressor start-up
2. Condenser fan start-up
3. Evaporator fan(s) on
(continuously)
Cycle Off (Cut-out
temperature reached)
[Minimum 2 minutes]
1. Compressor off
2. Condenser fan off
3. Evaporator fan(s)
cycles on and off
Continue as
normal cycling
Cycle On (Cut-on
temperature reached)
[Minimum 2 minutes]
1. Compressor start-up
2. Condenser fan start-up
3. Evaporator fan(s) on
(continuously)
Defrost Start
Preprogrammed time interval
1. Compressor off
2. Evaporator fan(s) off
3. Condenser fan off
4. Defrost heater on
5. "dF" displayed
Defrost End
Defrost thermistor
reaches defrost
termination temperature,
or defrost timer reaches
1 hour
Defrost heater off

20
b) Timing Chart
Freezers – Energy Saving Operating Mode
nehwyaledputratsnafrotaropavednoceseviF
NO
FFO
NO
FFO
)+(laitnereffiD+tniopteS
)--(laitnereffiD+tniopteS
gninaemoN
FFO
NO NO
FFO
NO
FFO
NO
FFO
rotsimrehTtenibaC
rotsimrehTtsorfeD
rosserpmoC
naFresnednoC
n(s)aFrotaropavE
retaeHtsorfeD
.nim2
tratS(
aleD
)y
NOrewoP
emiT sruoh6
)elbatsujdA-tratStsorfeD(
.nim5
)yaleDniarD(
.nim5
)yaleDnaF(
rotacidnItsorfeD .nim8
)yaleDyalpsiD(
erutarepmeTnoitanimreTtsorfeD
.nim06<
)noitaruDtsorfeD.xaM(
tnettimretnI
noitarepO
)sdoirePFFOrosserpmoCllA(
tnettimretnI
noitarepO
)sdoirePFFOrosserpmoCllA(
TIME-TEMPERATURE CONTROL CHART [DURING ENERGY SAVING MODE] FOR
FREEZERS (ALL UNITS)
rehtegottratsesiwrehtodluownafdnarosserpmoc
*
*
*
*
Frame Heater(s)
.nim2
)NO.niM(
.nim2
)FFO.niM(